WIP CAPABILITIES

 has extensive WIP tracking and reporting features showing WIP items like moved, good out, rejects out, rework, transferred to rework and much more.  The reporting system for WIP data is completely customizable allowing you to slice and dice your WIP data in unlimited ways across unlimited numbers of parts.  All of it is exportable to spreadsheets.

SPC and SQC CAPABILITIES

SPC becomes a real part of factory management as collects, analyzes, monitors, generates warnings and even shuts down Lots or Operations based on incoming SPC data.  The paper blizzard associated with engineering data collection is over when you use to handle the information.

SCHEDULING CAPABILITIES

Using a Work Calendar, and Work Content on Travelers, predicts a ship date when a lot is kitted to the line and then constantly updates the predicted date while letting you know just how much ahead or behind the lot is running. Special on-line reports give Operators a quick look at what is in their queue at their workstation and from this list they can choose the hottest lots currently on the line to work on next.

ELECTRONIC QUARANTINE FEATURES

There are 5 levels of hold available within for MRB or any other purpose you might wish the system to stop work.

• Lot Number on Hold
• Part Number on Hold
• Operation on Hold
• Entire Traveler (and all its Lots), on Hold
• Future Hold  (Put a Lot on Hold when it reaches some future step.)

Both Lot Number Hold and Operation Hold can be configured to trigger automatically if SPC data goes out of Control.

ISO 9000  CONFIGURATION MANAGEMENT FEATURES

ISO 9000 compliance is supported via complete configuration management system, modeled after similar paper systems.  Operations, parts and part numbers, travelers and traveler numbers, etc. cannot be used by until they have been released.  For example, once a new traveler has been sent around and signed off, configuration management personnel with the right     security level and system password will release the traveler for use by factory floor operators.

BAR CODE ENABLED

 was designed from the ground up to be bar code driven. generates bar code labels for you on HP compatible laser     printers, using any desired format, readable by a myriad of different bar code wedges and readers.

It's all here and ready to use. If we can help in
anyway please give us a call.
 

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        REAL-TIME BENEFITS OF SHOP FLOOR CONTROL
 

INFORMATION ON YOUR DESKTOP

 This happens without your having to collect it or ask
 for it.  Now you have up to date information about
 factory floor loading, process centers that are in
 trouble and product movement through the work centers.
 You no longer have to rely on others to provide you
 with the information you need to focus your companies
 resources effectively.  You can clearly see for
 yourself what the picture is.  Everyone shares the
 same information.

INFORMATION ON THE DESKTOPS OF YOUR MANAGERS AND ENGINEERS

 These are people who need the information to make
 hands on decisions on a minute by minute basis.   They
 now have real-time information about the problems at
 their work centers.  They can see reject rates,
 inventory levels, cycle time problems, equipment
 problems, from any computer in the factory.

ON-LINE MANUFACTURING SPECIFICATIONS AND DRAWINGS

 It will bring current and up to date specifications
 and drawings onto the factory floor in an on-line mode
 for use by factory personnel.  No longer need you fear
 auditing agencies.   You will always have the most
 current information available on the floor.

REAL-TIME CONTROL OF YOUR FACTORY

 It will bring control to your factory, managing
 process flow and sequence, preventing out of
 specification processing, controlling employee
 qualification status by process, controlling equipment
 up/down status, thereby preventing use of out of
 calibration equipment.  No longer will you hear, "it
 just happened", because overriding system controls
 takes a password.

INCREASED THROUGHPUT AND YIELDS

 Factory  throughput is increased in many different
 ways.  First, visual inventory screens help you
 identify the bottlenecks in your factory.  If process
 yield issues are a problem, then SPC data is available
 to help with a solution. If the problem is an
 equipment downtime issue, then data is available to
 help solve that issue. If the problems are cycle time
 related the system holds data to help address that
 issue as well.  If data collection is a time consuming
 part of your process, then bar code data entry will
 reduce data input time as well.

     What Is It Costing You Because You Don't Have
              A Tool Like ?

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                PAY BACK  AND  BENEFITS

Real time data reporting makes you aware of what is
happening in your factory. Now you can respond to
situations as they develop rather than find out about
problems after it's too late to take incisive action.
You have a window down into the lowest levels of your
factory, right from your desk top.  With this window
you can manage all elements critical to your operation.
From your desk you can:

  - Lower Your In-line Inventory
  - Avoid Job Overruns
  - Spot Potential Bottlenecks Before They Develop
  - Predict When a Lot or Job Will Complete
  - Track Manufacturing Costs by Job, by Lot, by
    Operation, by Operator
  - Know the Current Yield of any Lot, Job or Operation
  - Spot Problem Areas before they produce scrap
  - Investigate Manufacturing Problems Without having
    to manually assimilate reams of data from numerous
    production areas
  - Instantly change job priorities and know they
    will be enforced
  - Change processing parameters and know it will be
    communicated to your operators
  - Much, much, more ...

All of these capabilities result in better, more timely
information which leads to better, more timely
decisions.  This in turn leads to direct, measurable
savings, allowing for a pay back period that is measured
in months.
 

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           STATISTICAL   PROCESS   CONTROL

Knowing where the product is in your factory, knowing
when the product is going to ship and other such
information is critical in helping managers make
informed, competent decisions.

However, Information about your process is just as
important as Production Information.  Process Control
is the key to a quality product, shipped on time.

When a process goes unmonitored, unmeasured and
uncorrected, very large and unpredictable swings in
both quality and quantity will occur.

SPC is a key element of and is integral
to the way the system works.  Engineering Data
Collection occurs every time parts are processed
through an operation in the factory.  From the
convenience of a computer terminal, Engineering can
review up to the minute process data from factory
Operations.  automatically keeps track of
operations and alarms when process parameters go out of
specification.

 Integrated WIP and SPC is one major benefit of running
    Manufacturing Execution Systems.
 

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              QUALITY ASSURANCE FEATURES

 supports and augments quality systems
presently in place in high tech. / high reliability
manufacturing environments.  delivers a
quality system in support of ISO 9000 for plants
looking to implement a quality system.

  - Enforces Configuration Management Systems.
  - Collects and Analyzes SPC data automatically.
  - Enforces Manufacturing Specifications.
  - Enforces Operator Qualification Status.
  - Keeps manufacturing process, procedures, drawings
    and technical specifications on-line at all times.
  - Makes quality auditing possible where it was
    previously a chore.
  - Easily Configured

CONFIGURATION MANAGEMENT

 is built from information supplied to it
by the user. knows nothing about your
factory until you build up a list of manufacturing
operations that are performed by your shop floor
employees.  This list holds information like:  Charge
number, Process/operation #, Revision Level, Default
technical specs, Document and drawing numbers necessary
for the operation.

As each operation is entered into it must
go through a release cycle similar to the release cycle
used for paper document systems. The significance of
this is that operations can only be released by
Configuration Management who has the release code for
 and the software will only allow for
released operations to be included in routings or
travelers. Like Operations, Routings or Travelers must
go through a release cycle before will
allow them to be used on the factory floor. This system
of release authorization enforces, via software,
compliance to Configuration Management principles.

SPC DATA COLLECTION AND ANALYSIS

When a process goes unmonitored, unmeasured and
uncorrected, very large and unpredictable swings in
quality and quantity will occur.

SPC is a key element of and is integral
to the way the system works.  Engineering Data
Collection and Analysis occurs every time parts are
processed through an operation in the factory.  From
the convenience of a computer terminal, Engineering can
review real-time data from factory operations and dump
data out to spread sheets and statistics packages.

Operations have Data Value control limits, Range Value
control limits and SPEC Limits that can be used to
control your factory.  As data is collected it is
compared against the three types of limits and
depending upon which values are exceeded or violated,
different actions can be triggered.  The system can be
configured to automatically put Operations on hold, or
Lots on hold that violate the limits. 
uses the WESTERN ELECTRIC "RUN RULES" to determine if
data is out of control.  This refers to the exceeds
limits as well as the 2 out of three, 4 out of 5 and 8
in a row methods of detecting unstable processes.

MANUFACTURING SPECIFICATIONS ENFORCEMENT

Specifications are enforced in the sense that the
routing or traveler calls out the sequence of
operations that are required to manufacture a product.
Deviation from that sequence is not possible without a
password that allows deviations.  No matter what the
operator does, maintains a COMPLETE
HISTORY of the AS BUILT configuration.

Travelers have an OPTIONAL and ALTERNATE steps
capability.  Once past the optional or alternate step,
the operator can not go back and choose the optional
step without knowing the password.  is
FLEXIBLE in that any operation may be repeated as
rework before going onto the next operation. The rework
is recorded with the history of the device or lot.

ON-LINE DOCUMENTATION

Manufacturing specifications are also enforced in that
technical specifications are put on screen whenever a
device or lot is checked into an operation.  The user
has the option of printing the specifications if
necessary to take back to their work station.  They
also have the option of reviewing any documentation
associated with the operation such as supporting
documents and drawings.  A nice feature of
 is that the operator doesn't have to know
these document titles intimately.  They appear as
documentation choices for the operator on check in.

OPERATOR QUALIFICATION ENFORCEMENT

Operators in the factory are assigned a qualification
status for different operations in the factory and
 will not allow operators to check into
operations they are not qualified for.

QUALITY AUDITING

 supports a very powerful form of on-line
data collection that is associated with the operation.
When ever a device or lot is checked out of an
operation will ask the operator to input
inventory information like starts, rejects, reject
categories and rework.  This input is kept to the
numeric keypad of a keyboard which is easy for
operators to master.  Once the inventory information is
collected will ask the operator for
Operational Information.  It can be any information
that quality, manufacturing, or engineering believes is
important.  It can be the batch code for a chemical
used to clean, etch, cement or solder for example.  It
can be a list of measurements made on a device or lot
of parts.  This information is captured to the database
and associated with the device and the operation. There
is immediate real-time feedback to the operator as to
whether the measurements they are entering exceed
control limits.  These limits are configured by users
with sufficient security rights.

There are monitoring screens that can be configured by
users to monitor data collected in real time from the
manufacturing line.  For example a process engineer
responsible for etching can watch in real time the data
that a factory floor operator is inputting as they go
about their job.  The monitor screen can be set up to
warn the engineer if data exceeds configurable
tolerances. Similar monitor screens can be configured
to watch inventory yield data by operation and by job.

EASILY CONFIGURED

This data collection is associated with an operation on
check out and can be changed at anytime.  There is
exceptional flexibility in the ability of the system to
collect data.  On a day to day or hour to hour basis it
is possible to change the data that is being collected
at an operation.  If a problem develops with an
operation data can be collected for several days, to
try and correlate it with other operational data from
other operations and then changed or abandoned as
necessary.  This is all possible with out programming
and is one of the most significant features of
 contribution to quality systems.

 Integrated SPC for your factory is a major benefit of
    Manufacturing Execution Systems.

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          SYSTEM FEATURES and FUNCTIONALITY

          The following is a partial list of
          features and functions.

OPERATION DEFINITION
   - Operation # (15 numeric-system assigned)
   - Operation Charge Number (20 ascii; used for cost
     accounting)
   - Operation Name (30 ascii)
   - Operation Documentation Number / Revision (20 ascii
     / 2 ascii)
   - Default Technical Specifications for on screen
     display
   - Linked on-line documentation for on screen display
     (unlimited)
   - Linked on-line drawings for on screen display
     (unlimited)
   - Reject Categories for operation (unlimited -
     20 ascii each)
   - Active vs Inactive Operations (ie. active
     operations can be synchronized with travelers)
   - New technical specs can be rolled across all
     synchronized travelers

PART DEFINITION
   - Part Type (30 ascii)
   - Part Number / Revision(30 ascii / 2 ascii)
   - Part Name (30 ascii)
   - Linked Part List (unlimited links - used to
     convert one part into another as it moves
     through factory)

TRAVELER DEFINITION
   - Traveler Class (4 classes; custom, production,
     rework, rework loop)
   - Part Number / Revision (traveler associated with a
     part number)
   - Traveler Number / Revision (30 ascii / 2 ascii)
   - Traveler Name (30 ascii)
   - Traveler Type (lot job - assembly job - auto
     checkin - time editable)
   - Step Number (unlimited steps)
   - Operation (from defined operations above)
       - Customized Technical Specifications for the
         operation
       - Post Release Editing of Technical Specs with
         separate release function & auto notification
       - Customized Data Collection for the Operation
         (SPC, operation logs, machine logs, etc.)
       - Step Types (required, optional, alternate,
         reworkable, rework, synchronized)

SALES ORDER DEFINITION
   - Sales Order Number (15 ascii)
   -
   - Part Number / Revision (associated with work order
     see part above)
   - Quantity
   - Date Due

OPERATOR DEFINITION
   - Operator Name (first, last, mi)
   - Operator Number (15 numeric)
   - Department Number (20 ascii)
   - Phone Number (14 ascii)
   - Operations Qualified to Perform (unlimited list
     associated with operations above)

BAR CODE DATA ENTRY
   - Bar Code Printing (prints travelers with embedded
     bar codes)
   - Bar Code Reading (reads bar codes printed on
     travelers and devices)

ON-LINE MANUFACTURING DOCUMENTATION AND DRAWINGS
   - Reads multiple word processing html and ascii text
     files
   - Reads multiple file types (JPEG, TIFF, GIF, etc.)

FACTORY FLOOR CONTROL
   - Trap and correct inventory errors at check in
   - Trap parts at the wrong operation
   - Restrict check in if not checked out from previous
     operation
   - Restrict check in to proper operation
   - Restrict check in to qualified operators
   - Display technical specifications to operator at
     check in
   - Auto Notify operators of changed technical
     specifications
   - Print technical specifications (if requested)
   - Display on-line documentation and drawings (if
     requested)
   - Collect reject data on check out
   - Verify inventory and correct errors on check out
   - Collect custom data on check out (SPC, machine
     logs, etc.)
   - Signal Operator when SPC data entered is out side
     defined control limits
   - Roll back capability for last step executed on
     traveler

SCHEDULING
   - Work Content per Operation (user configures
     days:hours:minutes for each operation)
   - Work Calendar (user configures hours available for
     work by day)
   - Work Content (if necessary, customize the
     days:hours:minutes for each operation on a traveler)
   - Work Index (user supplies an efficiency value for
     factory)
   - Projected Ship Date (calculated from Work Content
     for the lot when it starts on the line, Work
     Calendar of available hours to work, Work Index you
     want to run at.)
   - Predicted Ship Date (calculated from Work Content
     remaining on lot traveler, Work Calendar of
     available hours to work, Work Index you want to run
     at.)
   - Days Off Track (days either behind or ahead of
     Projected Ship Date, used to prioritize lots
     on-line)
   - Adjusted Ship Date (ship date for a lot to meet,
     system will indicate a new value for Days off
     Track.)

REPORTS
   - Traveler based Work In Process (WIP) reports
   - Lot specific WIP reports
   - Custom WIP reports
   - WIP by Charge Number
   - WIP by Operation
   - Activity Logs at Operation
   - Graphical and tabular views of line loading
   - SPC charts
   - SPC data monitoring reports
   - Yield charts
   - Yield monitoring reports
   - Reject reports
   - Pareto charts
   - Time on line reports
   - Time in queue reports
   - Scrap reports
   -  Report Writers can extract ad-hoc data
     (Access, , Crystal Reports etc.)

QUALITY ASSURANCE / CONFIGURATION MANAGEMENT
   - Full configuration management  support
   - Features ISO 9000 compliance support
   - SPC data acquisition, analysis and auditing
     capabilities

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                COMPANY BACKGROUND

Santa Barbara Analysis, has a 23 year background in
Semiconductor, Aerospace, Electronic and other
high-tech manufacturing environments.

Some of our past installations include systems for:
   - Hughes Aircraft
   - Spectrolab
   - Siemens
   - Pacesetter Systems
   - Applied Solar Energy Corp
   - TECSTAR
   - Micrel Semiconductor
   - Irvine Sensors
   - IBM / Essex Junction

We have experience across a broad range of
Manufacturing disciplines which lead to a solid
fundamental understanding of Manufacturing needs.
Process Engineering, Development Engineering,
Information Systems Development, Manufacturing
Management, and Manufacturing Systems Analysis and
Design are all areas of expertise.

We bring to the table a real world, vigorously tested
understanding of what information is needed on and off
the factory floor and how to best implement a system
that allows for operators to easily collect information
without impacting their productivity.

If there is anything that best differentiates
 from your other choices it is the
implementation of a system that shows an in-depth
understanding that factory floor information is input
by factory floor operators and that their interface
must be both elegantly simple and at the same time
complete. If the system is difficult for them to use
it slowly but surely becomes useless.

Our focus is to provide information systems that Work
the Way You Do.  A very simple statement but a very
powerful concept

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YOU SHOULD PICK UP THE PHONE AND CALL US RIGHT NOW!